Arrangement and method for simulating creping of tissue paper

ABSTRACT

Embodiments of the present disclosure relate to arrangements for simulating creping of tissue and methods for simulating creping of tissue.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. patent applicationSer. No. 14/162,824, filed Jan. 24, 2014, entitled “Arrangement andMethod for Simulating Creping of Tissue Paper, which is herebyincorporated by reference in their entirety.

BACKGROUND

The invention relates to an arrangement and method for simulatingcreping of tissue paper according to the preambles of the enclosedindependent claims.

SUMMARY

Creping is one of the important processes on a tissue machine. The sheetis adhered to a Yankee cylinder surface where it is dried. The driedsheet is then peeled off the cylinder surface with a doctor blade,whereby microfolds are created in the sheet. These changes in thestructure of the sheet influence greatly to the final sheet properties,such as softness and stretch. The creping process may often become abottleneck in the production that decreases machine speed andefficiency. In order to improve the creping process various chemicalsmay be added to the surface of the Yankee cylinder. Possible chemicalsare adhesives, release agents and modifiers. It is possible to add oneor more of these chemicals to the surface of the Yankee cylinder foroptimal creping performance at varying process situations.

One problem is the testing of the chemicals which are employed in thecreping process. Quite naturally, testing of new chemicals or newdifferent chemical combinations is preferably not made by using realproduction apparatus. Thus there is a need for test apparatuses withwhich different creping chemicals may be tested. One experimental rigfor trialing new creping chemicals and determining their optimumconditions is presented by Ho, J., Hutton, B, Proctor, J. and Batchelor,W.: “Development of a tissue creping test rig”, Chemeca 2007, IChemEA(2007), p. 1334-1340. However, the proposed solution does not provide anenvironment which is representative to real process conditions. Forexample, the speed of the process is much lower than in real life.

An object of the present invention is to minimise or even completelyeliminate the problems existing in the prior art.

One object of the present invention is to provide an arrangement andmethod for simulating creping of tissue in as real process conditions aspossible.

Another object of the present invention is to provide an arrangement andmethod for testing different process chemicals in creping of tissue.

These objects are attained with a method and an arrangement having thecharacteristics presented below in the characterizing parts of theindependent claims.

Typical arrangement according to the present invention for simulatingcreping of tissue, the arrangement comprising

a sled with a test surface, which sled is arranged to travel along alinear path;

heating means for heating the test surface;

a spray unit with at least one spray nozzle, the spray unit arrangedalong the linear path of the sled, and the at least one spray nozzlearranged to spray a chemical on the test surface;

a creping unit comprising a creping blade, the creping unit arrangedalong the linear path of the sled after the spray unit and the crepingblade arranged to pass over the test surface when the sled passes thecreping unit; and

measurement means for measuring data related to force between thecreping blade and the test surface.

Typical method according to the present invention for simulating crepingof tissue, the method comprising

heating a test surface to a predetermined temperature;

transferring the test surface along a linear path;

spraying a chemical to the test surface;

arranging a creping blade to pass over the test surface after thespraying of the chemical; and

measuring and collecting data related to force between the creping bladeand the test surface.

All the described embodiments and advantages apply both for thearrangement and the method according to the present invention, whenapplicable, even if not always explicitly stated so.

Now it has been surprisingly found out that the creping process, itsconditions and relevant forces between the creping blade and the Yankeecylinder can be effectively simulated by applying the chemical to betested onto a heated test surface which is transferred along a linearpath so that it passes a creping blade. Data related to force betweenthe creping blade and the test surface, such as orthogonal force, ismeasured and collected, which gives good and reliable estimate of forcesprevailing in real life process conditions. The linear path of the testsurface provides a possibility to use high test speeds, which bettercorresponds to the industrial process speeds. The arrangement of thepresent invention is designed to closely approximate various productionvariables, such as temperature of the Yankee cylinder surface;concentration, formulation and time-to-dry of the applied chemical; aswell as different creping blade parameters. All this provides new andexciting possibilities for testing of different chemicals and chemicalcompositions for creping of tissue.

According to one embodiment of the invention the test surface is a partof a test plate, which is detachably arranged to the sled transferredalong the linear path. The test surface, and optionally also the testplate, can be made of any material which corresponds to a Yankeecylinder material used in industrial production of tissue. The testsurface may be made of cast iron, stainless steel or a metallizedcoating on a cast iron plate. According to one embodiment the testsurface is slightly sloping in the leading edge and/or rear edge, seenin the direction of the transfer. The height difference between theleading/rear edge of the surface and the middle part of the surface maybe 1-4 mm, preferably approximately 2 mm. The slightly sloping form ofthe test surface ensures a smooth travel of the creping blade over thetest surface.

The test surface is heated by using heating means. According to oneembodiment of the invention the heating means comprises a heatingelement, which is arranged to the sled. Typically the test surface isheated to a temperature of at the most 135° C., preferably 80-130° C.,more preferably 90-115° C., even more preferably 95-110° C. Thetemperature of the test surface is preferably adjustable. Adjustmentstep may be, for example, 0.1° C. The temperature of the test surfacemay be controlled by using a temperature sensor. In one embodiment, astationary infrared (IR) temperature sensor may be arranged over thetest surface at the start position of the test surface. If thetemperature of the test surface exceeds a predetermined threshold value,the heating is interrupted, e.g. by discontinuing power supply to theheating means. The predetermined threshold value can be chosen on basisof the process to be simulated. For example, the heating can beinterrupted when the test surface temperature exceeds 120° C.

An isolation layer may be arranged between the test plate with the testsurface and the heating means, in such a manner that a direct contactwith the test plate and the heating means is avoided. The isolationlayer may be made of, for example, Teflon or silicon cloth.

The test surface is arranged to a sled, which is moved along a linear,preferably horizontal, path. The test plate with the test surface may befastened to the sled by using any suitable fastening means, such asangle brackets, bolts, screws, pins, or the like. Preferably the sledcomprises a stopper plate in the in the leading end and/or rear end ofthe sledge, seen in the direction of transfer, in order to keep the testsurface securely positioned on the sled. The sled may comprise transfermeans, such as adjustable V-bearings with eccentric shafts. Thesetransfer means can be fitted to the grooves of the guide rail. The sledmay optionally comprise a lubricating box between the bearings forapplying grease or oil on the grooves of the rail. The sled may beoperated by sled drive means, such as a servomotor or the like, and atiming belt or the like.

Speed of the sled along the linear path may be 5-35 m/s, preferably 5-30m/s, more preferably 10-25 m/s, when it passes the creping blade. Thismeans that the test surface is transferred with a speed of 5-35 m/s,preferably 5-30 m/s, more preferably 10-25 m/s, while the creping bladepasses over the test surface. According to one embodiment the speed ofthe sled, and the test surface, may be in the range 6-12 m/s. The sledstarts from a determined zero position in the first end of the guiderail and is accelerated to a predetermined first speed before it passesthe spray unit. The acceleration of the sled may be at the maximum of 30m/s², preferably 5-30 m/s², more preferably 10-30 m/s², and itsdeceleration at the maximum of 34 m/s², preferably 5-34 m/s², morepreferably 15-34 m/s². According to one embodiment the drying speed ofthe chemical(s) applied at the spray station can be influenced andselected by selecting the speed of the sled and/or the temperature ofthe test surface. In this manner various different process conditions ofcommercial production operation can be successfully simulated.

The spray unit comprises at least one spray nozzle, optionally aplurality of spray nozzles. The spray nozzles are arranged to spray atleast one chemical or chemical mixture on the heated test surface whenthe sled with the test surface passes the spray unit. The appliedchemical, such as adhesive, begins to dry on the heated test surface,thus corresponding to the situation in industrial production, where theadhesive is applied on the heated surface of a Yankee cylinder. Thespray unit may be arranged on the side of the linear path of the sled orabove the linear path of the sled. For example, the sled may pass underthe spray nozzle of the spray unit, the spray nozzle applying thechemical to the test surface. According to one embodiment of theinvention the arrangement can comprise a plurality of separate sprayunits, arranged along the linear path of the sled. The spray units maybe operated individually or in communication which each other. Pluralityof nozzles in one spray unit and/or plurality of spray units providepossibility to test even complex combinations of different chemicals.

The spray nozzle of the spray unit is any suitable liquid nozzle.Preferably the spray nozzle is replaceable. Change of spray nozzleprovides for possibility to test easily different spray patterns and/ordifferent flow rates, which increases the flexibility of thearrangement. The spray nozzle of the spray unit may be connected to apressure tank, which comprises the chemical to be sprayed. The pressuretank may be connected to a compressed air system or inflated manually.Flow rate and/or feeding pressure of the chemical may be controlled andadjusted according to the need.

The creping unit comprises the creping blade, which is arranged to passover the test surface when the sled passes the creping unit. The crepingunit is situated after the spray unit and after the optional press unit.The creping blade is arranged to a blade holder and attached withsuitable attachment means to the holder, for example with screws. Thesize of the creping blade may be selected according to suit the othermeasurements of the arrangement. The length of the creping blade may be,for example, 100-200 mm, preferably 110-150 mm, and the width of thecreping blade may be, for example 80-120 mm, preferably 90-110 mm. Thethickness of the creping blade may be at least 0.8 mm. Similarly theangle between the creping blade and the test surface may be adjustedaccording to the need. In this manner it is possible to test differentcreping blade compositions, grind angles and/or creping pocket angles,and their effect to the creping result.

At the creping unit the sled with the test surface passes underneath thecreping blade of the creping unit. The creping blade comes into contactwith the slightly sloping leading edge of the test surface, whereby thecreping blade bends and creates a vertical load as the creping bladereaches the middle part of the test surface. When a test tissue sheethas been applied on the middle part of the test surface at the pressunit, it has been dried to correct consistency, i.e. moisture content,when the test surface reaches the creping unit and the test tissue sheetis creped off the test surface by the creping blade. During the crepingthe creping blade is subjected to a horizontal creping force.

According to one preferred embodiment of the invention creping blade isarranged to exert a vertical load to the test surface when passing thetest surface. The load force of the creping blade against the testsurface may be adjusted by using load adjusting means, such as loadadjustment screw(s). The creping unit may comprise or it may be infunctional contact with measurement means, which measure data related tothe force between the creping blade and the test surface. Themeasurement means may comprise a first load cell and a second load cell,which both are arranged into a functional contact with the crepingblade; collection means for collecting and preserving the obtained data;and calculation means for calculating on basis of the obtained data theforces relevant in creping, such as orthogonal forces. According to onepreferred embodiment of the invention the creping unit comprisespreferably at least a first load cell for measuring the vertical load onthe creping blade and a second load cell for measuring the horizontalload during the creping, i.e. for measuring the load in horizontaldirection. The first and second load cells convert the load forces intoelectrical signals which are transmitted to the data collection means,where they are handled and stored. From the collected data final loadforce results may be calculated by using calculation means.

According to one advantageous embodiment of the present invention thearrangement comprises a press unit with a press roll, the press unitbeing arranged between the spray unit and the creping unit along thelinear path of the sled and the press roll being arranged to pass overthe test surface when the sled passes the press unit. The press roll isoperated by press roll drive means, such as a servomotor or the like.The press roll is rotating at a suitable speed and pressed against thetest surface when it passes the press unit. The press force of the pressroll towards the test surface is preferably adjustable by using pressforce adjusting means, such as springs and/or force adjustment screw(s).The maximum pressing force between the press roll and the test surfacemay be selected depending on the overall arrangement configuration, butit may be, for example, 2000-10 000 N, preferably 6000-8000 N.

The press roll preferably comprises a felt, which is arranged around thepress roll circumference. The felt may be attached by using suitableattachment means, such as clamping edge or the like. A test tissue sheetmay be applied on the felt surface. When the test surface passes thepress unit, the press roll is pressed against the test surface and thetest tissue sheet is pressed against the test surface, on to which itadheres. According to the one preferred embodiment of the invention thetest tissue sheet is applied onto the test surface after the spraying ofthe chemical, whereby the creping blade of the creping unit removes thetest tissue sheet from the test surface while passing the surface. Thetest tissue sheet is transferred from the press roll of the press unitto the heated test surface by a combination of hydraulic forces andadhesive forces.

According to one preferred embodiment the felt may be wetted beforeapplication of the test tissue sheet. The pressing force of the pressroll both dewaters the test tissue sheet and transfers the test tissuesheet from the wet felt to the heated test surface. For example, thepress roll dewaters the test tissue sheet to consistency of 37-45%. Amore accurate estimate about behavior of the tissue in real processconditions may thus be obtained.

According to one embodiment of the present invention the sled isaccelerated to a predetermined second speed after the press unit andbefore the creping unit. The sled exits the pressure unit before itaccelerates to the second speed, i.e. creping speed. The accelerationstage to the second speed ends before the creping unit such that thesled passes the creping unit at constant predetermined second speed. Thetest tissue sheet dryness and the film strength of the applied chemicalmay adjusted or corrected by adjusting and selecting the sled speedbetween the press unit and creping unit, which naturally determines thetime lapsing between the two units as well as the performed operations.Typically the second speed is higher than the first speed, but is someembodiments the first speed and the second speed are substantially same,or in some embodiments the first speed may even be higher than thesecond speed. In this manner, the arrangement and the method provideextensive possibilities to test and simulate different processconditions, and to gain understanding of the creping process.

After the creping unit the sled is decelerated and stopped beforereaching the second end of the guide rail.

The test tissue sheet may be freely chosen. By using the arrangement andthe method according to the present invention it is easy to test tissuesheets with different consistency, density and/or fiber composition.Because the test procedure is simple and fast to perform, and the amountof tissue sheet and chemicals is small, there are few economical and/ortime bound limitations for testing of different combinations. Forexample, test tissue sheet can be formed by using dynamic sheet former,which is capable of controlling sheet basis weight, MD/CD fiberorientation and uniformity. Typically the test tissue sheet, which istested by using the arrangement described in this application, has notbeen fully dried before simulation testing. The test tissue sheet may bedewatered to a consistency of approximately 50%, before it is applied onthe surface of the pressure roll. Thus the obtained results closelymatch the commercial operations.

According to one preferred embodiment the sled is arranged to travelalong a linear horizontal guide rail. The guide rail has a first end anda second end, and its length may be freely selected, as long as the sledis able to reach the desired speed before the creping unit anddecelerate before the second end of the guide rail. Typical length ofthe guide rail may be 3-10 meters, preferably 4-6 meters. The guide railis preferably firmly supported and anchored to the ground by using anysuitable supporting means and fastening means. The guide rail may be analuminum profile. Preferably the guide rail comprises grooves and thesled comprises bearings, which are fitted to the grooves of the guiderail.

The drive and location devices of the arrangement generally comprise thedrive means of the press roll and the sled, a timing belt withcalibrated teeth as well as inductive sensors. Servomotors are preferreddrive means because they enable accurate positioning of the sled alongthe guide rail and the rotational position of the press roll. The timingbelt is also used for determining the accurate linear position of thesled along the guide rail. The location devices comprise also inductivesensors, positioned for example at the press unit and at the second endof the guide rail. The inductive sensors may be used to determine theposition the sled and/or to confirm that the servomotor positioncalculations are correct.

According to one preferred embodiment of the present invention thearrangement is semi-automatic and can be operated by one processoperator. Heating means, spray unit on/off, drive means of the pressunit and the sled may be connected to and operated through an operatorpanel of central control means, such as personal computer. Spraypressure of the spray nozzle of the spray unit as well as pressing forceof the press roll of the press unit and load of the creping blade arenormally set manually. Also the application of the test tissue sheets onthe press roll is done manually.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is described in more detail below with reference to theenclosed schematic drawing, in which:

FIG. 1 shows an arrangement according to one embodiment of theinvention, seen from side.

DETAILED DESCRIPTION

FIG. 1 shows an arrangement according to one embodiment of theinvention, seen from side. The arrangement 1 comprises a sled 2 with atest surface 3, which can be heated to a desired test temperature. Thesled 2 is transferred along a linear path with the aid of a timing belt4, arranged around an idle roll 5 and a drive roll 5′. The sled 2 isshown in the zero position at the first end of the linear path. The dashline shapes 2′, 2″ represents the sled in various positions during theperformance of the method.

At least on chemical is applied on the heated test surface 3 of the sled2 by using a spray unit 6, which is represented by an arrow in FIG. 1.The sled 2 passes the spray unit 6, and the at least one chemical issprayed from a spray nozzle (not shown) on the test surface 3.

After the spray unit 6 the sled 2 pass a press unit 7 which comprises apress roll 8. The press roll 8 rotates at the predetermined speed and ispressed against the test surface 3, when the sled 2 passes the pressunit 7. The press force of the press roll 8 towards the test surface 3is adjustable with press force adjusting means 9, such as adjustmentscrew(s) or spring(s). A test tissue sheet (not shown) is arranged onthe surface of the press roll and pressed against the heated surface ofthe test surface 3.

The test tissue sheet is creped off from the test surface 3 at a crepingunit 10. The creping unit 10 comprises a creping blade 101 as well as afirst load cell 11 for measuring the vertical load on the creping blade101 and a second load cell 12 for measuring the horizontal load duringthe creping.

The location device for determining the position of the sled 2 along thelinear path comprises inductive sensors 13, 13′ and a stopper 14 at thesecond end of the linear path.

It should be noted that the arrangements, its different units andindividual parts and components are not presented in scale in FIG. 1.Some units, parts and components are presented off-scale, typicallylarger, in order to give a clear presentation.

Even if the invention was described with reference to what at presentseems to be the most practical and preferred embodiments, it isappreciated that the invention shall not be limited to the embodimentsdescribed above, but the invention is intended to cover also differentmodifications and equivalent technical solutions within the scope of theenclosed claims

1. Method for simulating creping of tissue, the method comprisingheating a test surface to a predetermined temperature, transferring thetest surface along a linear path, spraying a chemical to the testsurface, arranging a creping blade to pass over the test surface afterthe spraying of the chemical, measuring and collecting data related toforce between the creping blade and the test surface.
 2. Methodaccording to claim 1, characterized in applying a test tissue sheet ontothe test surface after the spraying of the chemical, whereby the crepingblade removes the test tissue sheet from the test surface while passingthe surface.
 3. Method according to claim 1, characterized intransferring the test surface with a speed of 5-35 m/s, preferably 5-30m/s, more preferably 10-25 m/s, while the creping blade passes over thetest surface.
 4. Method according to claim 1, characterized in heatingthe test surface to a temperature of at the most at the most 135° C.,preferably 80-130° C., more preferably 90-115° C., even more preferably95-110° C.
 5. Method according to claim 1, characterized in measuring aforce between the creping blade and the test surface, converting theforce into electrical signals, and transmitting the signals to the datacollection means.